Input Shaft Cover

Input Shaft Cover

Special tools, testers and auxiliary items required

• Seal Ring Extractor (T40014)

• Pressure Stand (T40099)

• Assembly Tool (T10219/1)

• Thrust Plate (VW 401)

• Tube 37 mm Dia. (VW 416 B)

• Ice spray

• Protective gloves

• Protective goggles

Removing

• Input shaft removed. Refer to => [ Input Shaft ] Input Shaft.

• (T40099) adapted for using with the 0AW transmission. Refer to => [ Pressure Stand, Adapting to 0AW Transmission ] 0AW Transmission.

- Pull oil pipe - arrow - upward and out to avoid damage.






- Check all eight bolts - arrows - on the (T40099).






• Bolts must be installed flush to 25 Nm. Refer to assembly instructions for pressure stand (T40099)

- Insert input shaft in (T40099).






- Rotate (T40014) by hand into shaft seal until the tool has a good hold in the shaft seal. Then tighten puller with an open-end wrench.

- You can pull out shaft seal a short distance by screwing in rear bolt - arrow -.

- Re-tighten (T40014) so that puller engages securely in shaft seal again and continue turning bolt to pull out shaft seal.

- Repeat the process until the shaft seal is removed completely.

- Remove the locking ring from the input shaft cover - 1 -.






- Measure and note thickness of removed locking ring.

• When installing, locking ring must be replaced with a new locking ring of same the thickness.

- Clean the contact surface on the input shaft cover.

Danger of getting burned.

• Always wear gloves and eye protection!

- Cool the hallow shaft, for example with ice spray, through the opening - arrow 1 - for the removed oil pipe - 1 - on the inner bearing seat - arrow 2 - - 2 - (transmission input shaft ball bearing).






• The input shaft represented in section here.

• The input shaft must be cooled so that the input shaft ball bearing can be pressed off more easily and not be damaged.

- Clean the surface on the (T40099).






- Place the input shaft in the pressure stand.

• The contact surface on the input shaft cover must be flush.

• Make sure there are no shavings or dirt on the input shaft cover contact surface and on the surface of the (T40099).

- Also cool the input shaft from outside - arrow - with ice spray, for example.

• The input shaft must be cooled so that input shaft ball bearing can be pressed off more easily and not be damaged.

- Place the input shaft together with the (T40099) on the hydraulic press pressure plate.

• (T40099) should lie on as much surface of hydraulic press as possible.

- Hold the input shaft from underneath and push it at the same time out of the cover using the hydraulic press.






- Place input shaft on assembly tool (T10219/1).






Installing

- Replace the input shaft ball bearing. Refer to => [ Input Shaft Ball Bearing ] Input Shaft Ball Bearing.

- Place the input shaft cover on input shaft and press on by hand as far as possible.






- Place input shaft - B - on (VW 401).






Place input shaft straight and centered under hydraulic press thrust disc; otherwise input shaft can tip to the side when cover is pressed on.

- With hydraulic press, press input shaft cover - A - with (VW 416 B) onto input shaft up to stop.

- When installing, circlip - A - must be replaced with a new circlip of the same thickness.






• The locking ring must fit inside the bottom of the groove.

- Check wear on transmission components. Refer to => [ Input Shaft, Checking for Wear ] Final Drive, Differential (0AW Continuously Variable Transmission).

- Replace O-ring on oil pipe - 2 -.






• The oil pipe is pressed into the input shaft with the O-ring - 2 -.

• Oil pipe must engage noticeably, rotor blades - arrow A - on oil pipe must lie completely in input shaft.

- Press oil pipe - arrow - down into input shaft to stop.






• The distance from the end of the oil pipe up to the input shaft is approximately 11.5 mm - a - when the oil pipe is inserted all the way.

• If the dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.

• If the dimension is larger, it is not pushed in far enough.

If the oil pipe is damaged, starting problems or a transmission malfunction will result.

• The input shaft may not be placed on the protruding oil pipe - arrow -.